Suspended ceiling with cup type cap



Sept. 12, 1967 D. .1. DEINHART ETAL 3,340,552

SUSPENDED CEILING WITH CLIP TYPE CAP 2 heets-Sheet 1 Filed May 17, 1965 INVENTORS Dov i d J. Dei nhurt John P. C 10 r k Pc'r'r i ck R. Lov u I I o ATTOR N EY SUSPENDED CEILING WITH CLIP TYPE CAP Filed May 17, 1965 2, Sheets-Sheet INVENTORS David J. Deinhort John P Clark Patrick R. Lovullo azz-P ATTORN EY United States Patent 3,340,662 SUSPENDED CEILING WITH CUP TYPE CAP David J. Deinhart and John P. Clark, Williamsville, and Patrick R. Lovullo, Buffalo, N.Y., assignors to National Gypsum Company, Butfalo, N.Y., a corporation of Delaware Filed May 17, 1965, Ser. No. 456,122 8 Claims. (Cl. 52-476) disposed a substantial distance below existing building ceiling elements. Other systems involve aflixing ceiling panels adjacent and substantially abutting the bottom face of existing ceiling elements, such as joists.

The present invention is directed to an improvement adaptable to either system. Briefly, the present invention consists of elongate Z metal runners having a substantially vertical middle section with spaced small holes for the reception and holding of the ends of perpendicularly disposed cross T runners. The lower edge of the Z-runner vertical middle section is formed in an elongate raised ridge directed away from the Z-runner bottom flange, and an elongate Z-runner cap is snap-locked onto the raised ridge and the bottom flange outer edge, providing a finished exposed support for theedges of two adjacent rows of ceiling panels.

An object of the invention is to provide a novel, economical and highly efficient ceiling panel suspension systern.

A further object is to provide a novel system having markedly improved and simplified means for removing individual panels, providing accessibility to pipes, wiring, and other utilities disposed above and normally hidden by the panels.

A further object is to provide a system having a readily removable bottom main runner cap which when mounted provides equal support to panels on both sides of the runner.

These and other objects of the invention will be more apparent when considered in relation to the preferred embodiments as set forth in the specification and shown in the drawings in which:

FIG. 1 is an isometric view of a direct-to-joist ceiling grid system, with ceiling panels, constructed in accordance with and embodying the present invention.

FIG. 2 is an enlarged isometric view of the elements of the novel grid system depicting their manner of being assembled.

FIG. 3 is an isometric view of a drop-ceiling construction embodying the grid system of the present invention.

FIG. 4 is a vertical sectional view of two adjacent main Z-runners having a cross T mounted therebetween, showing in broken lines the manner steps in removing a Z- runner cap and a cross T for rapid removal and replacement of ceiling panels with a suspension system constructed in accordance with the invention.

Referring to FIGS. 1 and 2, a plurality of elongate, parallel, galvanized steel, main Z-runners 10, each having a bottom horizontal flange 12, a substantially vertical central web 14, and an oppositely directed horizontal top flange 16, are aflixed as by nails (not shown) extending through top flange holes 18 into the bottom faces of a "ice plurality of parallel wooden joists 20 extruding perpendicularly to the Z-runners 10'.

The Z-runner bottom flange 12 provides means for supporting the edge of a ceiling panel 22 disposed thereon. Ceiling panels 22 will commonly be of a size of from one foot by one foot up to two feet by eight feet. The present invention is particularly advantageous in supporting panels of two feet by two feet and two feet by four feet. On the opposite side of the Z-runner, an adjacent ceiling panel 22 has an edge supported on an elongate Z- runner cap 24 mounted on the bottom of Z-runner 10. Z- runner cap 24 consists of a painted or otherwise predecorated bottom face 26 having a width substantially twice the width of bottom flange 12. An upwardly and inwardly directed narrow edge 28 along one side of Z- runner cap 24 extends around the outer edge of Z-runner bottom flange 12, supporting one side of the Z-runner cap.

At the opposite edge of the bottom face 26, the Z-runner cap includes an upward reverse fold connecting the bottom face 26 to an upper section 30 having a substantially horizontal elongate web section 32 of a width substantially equal to the width of the Z-runner bottom flange 12. Upper secion 30' also includes an upwardly directed inner edge 34.

Inner edge 34 and the bottom portion of Z-runner central web 14 are both formed with complementary elongate ridges, 36 and 38 respectively, whereby Z-runner cap 24, when mounted, is firmly held to the bottom of Z- runner 10 by the narrow edge 28 extending around the edge of bottom flange 12 and the complementary ridge 36 of the Z-runner cap fitting firmly around the ridge 38 of the Z-runner. The complementary ridges 36 and 38 are formed of a shape and size, dependent upon the degree of resilience of the sheet steel used, such that the elongate Z-runner cap 24 may be readily snapped into firmly mounted condition by placing the narrow edge 28 around the edge of flange 12 and pivoting the cap upwardly, as shown in broken lines in FIG. 2, until the Z-runner cap ridge 36 engages and locks onto Z-runner ridge 38. Removal and replacement of the Z-runner cap 24 may be repeated as often as desired or necessary during the life of a ceiling, such as for repairing utilities which may be disposed above the ceiling panels 22.

In the preferred form of the invention, cross Ts 40 are also used, extending perpendicularly between adjacent parallel Z-runners -10, at each end junction of two adjacent panels 22. The elongate cross Ts 40 are, throughout a major extent, of an inverted T cross section, with a vertical web 42 and two oppositely directed bottom flanges 44, 46 for supporting the end edges of the adjacent panels 22. At each end of each cross T 40, the vertical web 42 has an end portion 48 which extends beyond the extent of bottom flanges 44 and 46, which does not extend downwardly as far as web 42, and which is formed with a downwardly opening slot 50 therein. Slot 50 is -'located at a distance from the end of flanges 44 and 46 equal to the width of the Z-runner bottom flange 12.

The Z-runner vertical central web 14 has a plurality of spaced, parallel; vertical slits 52 at least as tall as the end portion 48 and'as wide as the thickness of two end portions 48. Cross Ts 40 are mounted between adjacent parallel Z-runners 10 by the insertion of one end portion 48 into a slit 52 of one Z-runner and the other end portion 48 into a slit 52 of the parallel adjacent Z-runner. This insertion can be made between fixedly spaced Z- runners by the fact that the cross T 40 can be inserted in the first slit 52 to an extent beyond the slot 50 so the other end can be started into its respective slit 52. When it has been inserted to the extent that slot 50 is disposed immediately within the slit 52, the same condition will exist at the other end of the cross T, and the cross T may clips 62 which extend over channel 60 and attach to the Z-runner top flange 16. Many forms of such clips are known and available. Channels 60 are suspended by wires from a substantially higher existing ceiling, forming what is commonly referred to as a drop-ceiling construction. In all other respects, the Z-runners 10, Z-runner caps 24, and cross Ts 40 are constructed and combined to support panels 22 in a manner similar to the structure of FIG. 1.

In FIG. 4, there is depicted the Z-runner caps 24 and the cross Ts 40 in final mounted disposition, and also, in broken line, their respective positions as they are being dismounted. It will be noted that Z-runner cap 24 is dismounted without need of removal of any other parts. On the other hand, the cross T 40 can, if desired, be removed, as depicted, without removal of any other parts. Accordingly, such a system is highly adaptable to all contingencies in mounting, use, and demounting.

Having completed a detailed disclosure of the preferred embodiments of our invention so that those skilled in the art may practice the same, we contemplate that variations may be made without departing from the essence of the invention or the scope of the appended claims.

We claim:

1. A ceiling panel suspension system comprising a plurality of main elongate, rigid Z-runners and a plurality of elongate, rigid Z-runner caps each adapted for snap-on attachment to one of said Z-runners, each said Z-runner having a generally vertically disposed central web, a top flange directed horizontally from one side of the top of said central web and a bottom flange directed horizontally from the opposite side of the bottom of said central web, each said Z-runner cap having a width substantially twice the width of said bottom flange and having means on one edge for supporting said one edge by the outer edge of said bottom flange, the opposite edge of said Z runner cap having an upper section of the Z-runner cap affixed thereto by a reverse fold of the material of said Z-runner cap, said upper section having a horizontal section of a width substantially equal to the width of said bottom flange and a generally vertical section extending upwardly from the inner edge of said horizontal section,

said vertical section'of said Z-runner cap and said vertical central web of said Z-runner each having complementary raised locking means, whereby said Z-runner caps may be readily demountably aflfixed to said Z- runners by first engaging said edge engaging means on said bottom flange edge and then engaging said Z-runner cap raised locking means with said complementary central web raised locking means.

2. A suspension system as defined in claim 1 wherein said Z-runner cap supporting means on one edge consists of a narrow elongate edge folded upwardly and inwardly, forming a Z-runner bottom flange edge retaining groove of a depth substantially no greater than suflicient to support the edge of said Z-runner cap when said Z- runner cap is attached to said Z-runner.

3. A suspension system as defined in claim 1 wherein said complementary raised locking means of said Z-runner cap and said Z-runner consists of a complementary elongate raised rib in each.

4. A suspension system as defined in claim 1 further comprising interlocking cross Ts having a vertical Web, and two oppositely directed bottom flanges, said vertical we'b having at each end an end portion which extends beyond the extent of the two bot-tom flanges, each said end portion having means for locking said cross T s to said Z- runners with said cross T bottom flanges disposed perpendicular to and abutting the side edges of said Z-runner caps.

5. A room ceiling comprising a plurality of rectangular ceiling panels supported on a ceiling panel suspension system as defined in claim 1.

6. A room ceiling comprising a plurality of rectangular ceiling panels supported on a ceiling panel suspension system as defined in claim 2.

7. A room ceiling comprising a plurality of rectangular ceiling panels supported on a ceiling panel suspension system as defined in claim 3.

8. A room ceiling comprising a plurality of rectangular ceiling panels supported on a ceiling panel suspension system as defined in claim 4.

References Cited UNITED STATES PATENTS 2,942,704 6/1960 Stubbs 52-476 2,946,414 7/1960 Gordon et a1. 52-476 3,084,401 4/1963 Findlay 52476 FRANK L. ABBOTT, Primary Examiner.

G. W. HORNADAY, Assistant Examiner. 

1. A CEILING PANEL SUSPENSION SYSTEM COMPRISING A PLURALITY OF MAIN ELONGATE, RIGID Z-RUNNERS AND A PLURALITY OF ELONGATE, RIGID Z-RUNNERS CAPS EACH ADAPTED FOR SNAP-ON ATTACHMENT TO ONE OF SAID Z-RUNNERS, EACH SAID Z-RUNNER HAVING A GENERALLY VERTICALLY DISPOSED CENTRAL WEB, A TOP FLANGE DIRECTED HORIZONTALLY FROM ONE SIDE OF THE TOP OF SAID CENTRAL WEB AND A BOTTOM FLANGE DIRECTED HORIZONTALLY FROM THE OPPOSITE SIDE OF THE BOTTOM OF SAID CENTRAL WEB, EACH SAID Z-RUNNER CAP HAVING A WIDTH SUBSTANTIALLY TWICE, THE WIDTH OF SAID BOTTOM FLANGE AND HAVING MEANS ON ONE EDGE FOR SUPPORTING SAID ONE EDGE BY THE OUTER EDGE OF SAID BOTTOM FLANGE, THE OPPOSITE EDGE OF SAID ZRUNNER CAP HAVING AN UPPER SECTION OF THE Z-RUNNER CAP AFFIXED THERETO BY A REVERSE FOLD OF THE MATERIAL OF SAID Z-RUNNER CAP, SAID UPPER SECTION HAVING A HORIZONTAL SECTION OF A WIDTH SUBSTANTIALLY EQUAL TO THE WIDTH OF SAID BOTTOM FLANGE AND A GENERALLY VERTICAL SECTION EXTENDING UPWARDLY FROM THE INNER EDGE OF SAID HORIZONTAL SECTION, SAID VERTICAL SECTION OF SAID Z-RUNNER CAP AND SAID VERTICAL CENTRAL WEB OF SAID Z-RUNNER EACH HAVING COMPLEMENTARY RAISED LOCKING MEANS, WHEREBY SAID Z-RUNNER CAPS MAY BE READILY DEMOUNTABLY AFFIXED TO SAID ZRUNNERS BY FIRST ENGAGING SAID EDGE ENGAGING MEANS ON SAID BOTTOM FLANGE EDGE AND THEN ENGAGING SAID Z-RUNNER CAP RAISED LOCKING MEANS WITH SAID COMPLEMENTARY CENTRAL WEB RAISED LOCKING MEANS. 